JP5928929B2 - Automotive shock absorbing member and automotive body structure - Google Patents

Description

  The present invention relates to a shock absorbing member for automobiles configured by laminating discontinuous fiber reinforced resin layers on both sides of a continuous fiber reinforced resin layer. The present invention also relates to a vehicle body structure for a vehicle in which a fiber reinforced resin bumper beam press-molded in the front-rear direction and a fiber reinforced resin bumper beam extension press-formed in the vertical direction are coupled.

  Components such as automobile bumpers are constructed by alternately laminating a plurality of discontinuous fiber reinforced resin layers and a plurality of continuous fiber reinforced resin layers, so that the continuous fibers of the continuous fiber reinforced resin layer are intertwined and the strength is uneven. Even if it becomes, what smoothes it with the discontinuous fiber of a discontinuous fiber reinforced resin layer is well-known by the following patent document 1. FIG.

  In addition, when a fiber reinforced resin part is molded by pressing a sheet in which a resin layer containing discontinuous fibers is laminated on both sides of a continuous fiber layer with a mold, a resin containing discontinuous fibers is placed in a groove formed in the mold. It is known from Patent Document 2 below that the reinforcing ribs are integrally formed by inflow.

  Further, in an energy absorber formed by laminating a plurality of continuous fiber reinforced resin layers and formed into a truncated cone shape, a continuous fiber on the outer surface thereof is oriented in two directions of an axial direction and a circumferential direction. Is known.

Japanese Patent No. 3273968 Japanese Patent No. 3800974 Japanese Patent No. 4085980

  However, what was described in the said patent document 1 and the said patent document 2 is not disclosing about the relationship between the input direction of a collision load, and the orientation direction of a continuous fiber.

  Moreover, since the continuous fiber is arrange | positioned on the outer surface of an energy absorber, what was described in the said patent document 3 is in the direction inclined with respect to the input direction (axial direction of a truncated cone) of the preset collision load. When a collision load is input, the continuous fiber cannot support the collision load, and thus the strength may be significantly reduced.

  The present invention has been made in view of the above-described circumstances, and an object of the present invention is to provide an automobile impact absorbing member that can effectively absorb a collision load input from various directions.

  In order to achieve the above object, according to the present invention, a continuous fiber reinforced resin obtained by bonding continuous fibers oriented in a lattice shape in a first direction and a second direction orthogonal thereto with a first thermoplastic resin. The discontinuous fiber reinforced resin layer in which randomly oriented discontinuous fibers are bonded with a second thermoplastic resin is laminated on both sides of the layer, and the length of the discontinuous fibers is the length of the lattice of the continuous fibers. A shock absorbing member for a motor vehicle having a first characteristic that it is larger than the length of the diagonal line is proposed.

  According to the present invention, in addition to the first feature, there is proposed a shock absorbing member for an automobile characterized in that the continuous fiber reinforced resin layer has a fragile portion that partially reduces strength. The

  According to the present invention, in addition to the second feature, the continuous fiber reinforced resin layer includes a plurality of layers including a layer having the fragile portion and a layer not having the fragile portion. An automobile impact absorbing member is proposed.

  According to the present invention, in addition to any one of the first to third features, the discontinuous fiber reinforced resin layer wraps all both sides and ends of the continuous fiber reinforced resin layer. An automobile impact-absorbing member is proposed.

  According to the invention, in addition to any one of the first to fourth features, it is fifth that the first thermoplastic resin is nylon and the second thermoplastic resin is polypropylene. An automobile impact-absorbing member is proposed.

  According to the invention, in addition to any one of the first to fifth features, the discontinuous fiber reinforced resin layer includes a press-molded reinforcing rib. An absorbent member is proposed.

  According to the invention, in addition to any one of the first to sixth features, the discontinuous fibers of the discontinuous fiber reinforced resin layer are obtained by cutting the impact absorbing member into a predetermined length. A shock absorbing member for an automobile having a seventh feature is proposed.

  According to the invention, in addition to any one of the first to seventh features, the shock absorbing member is a bumper disposed between a vehicle body frame extending in the front-rear direction and a bumper beam extending in the vehicle width direction. The bumper beam extension is composed of an upper member and a lower member having a hat-like cross section when viewed in the front-rear direction, and is formed at both ends in the vehicle width direction of the upper member and covered with the discontinuous fiber reinforced resin layer. An automobile characterized in that the flange edge and the edge of the joint flange formed at both ends of the lower member in the vehicle width direction and covered with the discontinuous fiber reinforced resin layer are overlapped and laser-welded. A shock absorbing member is proposed.

  According to the present invention, in addition to the eighth feature, the first feature rib is integrally projected from the edge of the joint flange of the discontinuous fiber reinforced resin layer. A shock absorbing member is proposed.

  According to the invention, in addition to the eighth or ninth feature, the second reinforcing rib extending in the front-rear direction from the discontinuous fiber reinforced resin layer covering the outer surfaces of the upper member and the lower member is integrally formed. A tenth projecting portion is provided with a third reinforcing rib extending in a direction inclined with respect to the front-rear direction from the discontinuous fiber reinforced resin layer covering the inner surfaces of the upper member and the lower member. A characteristic automobile impact absorbing member is proposed.

  According to the invention, in addition to the tenth feature, a fastening flange extending in the vertical direction from the front end and the rear end of the discontinuous fiber reinforced resin layer covering the outer surfaces of the upper member and the lower member is integrated. A shock absorbing member for an automobile having an eleventh feature is proposed in which the front and rear fastening flanges are projected and connected by the second reinforcing rib.

  According to the present invention, in addition to the eleventh feature, there is proposed an automobile impact absorbing member according to the twelfth feature that a nut for coupling the bumper beam is inserted into the front fastening flange. The

  According to the present invention, in addition to the twelfth feature, there is proposed an automobile impact absorbing member according to the thirteenth feature in which the front end of the fastening flange is inclined toward the vehicle width direction outside. The

  According to the invention, in addition to any one of the features of the first to thirteenth aspects, the thickness of the discontinuous fiber reinforced resin layer before press molding is t0, and the discontinuous fiber reinforced resin layer is generally T1 <t0 <t2 where t1 is the thickness after press molding of the part and t2 is the thickness of the discontinuous fiber reinforced resin layer after the press molding of the second reinforcing rib and the third reinforcing rib. An automobile impact absorbing member is proposed, which is set as the fourteenth feature.

  According to the invention, in addition to any one of the first to seventh features, the impact absorbing member is a bumper beam extending in a vehicle width direction, and the bumper beam includes the continuous fiber reinforced resin layer. A plurality of U-shaped cross-sections formed in a U-shaped cross-section opening outward in the front-rear direction are continuous in the vertical direction, and the vertical ribs made of the discontinuous fiber reinforced resin layer are used to A shock absorbing member for an automobile is proposed, which has a fifteenth feature including a main body portion connected to a wall, a lower wall, and a bottom wall.

  According to the invention, in addition to the fifteenth feature, the bumper beam includes an initial load absorbing portion coupled to an outer side in the front-rear direction of the main body portion, and the main body portion includes the discontinuous fiber reinforced resin layer. A sixteenth feature is that the initial load absorbing portion is coupled to the main body portion by projecting a pin and melting the head portion of the pin penetrating the pin hole formed in the initial load absorbing portion. A shock absorbing member for an automobile is proposed.

  According to the present invention, a bumper beam made of fiber reinforced resin press-molded in the front-rear direction and a bumper beam extension made of fiber-reinforced resin press-formed in the vertical direction are from the impact absorbing member described in the first feature. The bumper beam and the bumper beam extension are combined in a vehicle body structure, and a pin projecting inward in the front-rear direction from the bumper beam is fitted into a pin hole formed in the bumper beam extension. A vehicle body structure for an automobile according to the seventeenth feature is proposed in which the bumper beam and the bumper beam extension are coupled by thermally crimping the head of the pin.

  According to the invention, in addition to the seventeenth feature, the bumper beam includes a discontinuous fiber reinforced resin layer laminated at least on the inner side in the front-rear direction of the continuous fiber reinforced resin layer. A vehicle body structure for an automobile characterized in that the pin is integrally provided with an eighteenth feature is proposed.

  According to the invention, in addition to the seventeenth or eighteenth features, the bumper beam and the bumper beam extension include a continuous fiber reinforced resin layer in which continuous fibers are oriented in two directions orthogonal to each other. A vehicle body structure having the nineteenth feature is proposed.

  According to the invention, in addition to the nineteenth feature, the bumper beam and the bumper beam extension include a discontinuous fiber reinforced resin layer laminated on the continuous fiber reinforced resin layer, and the discontinuous fiber reinforcement A vehicle body structure for an automobile according to a twentieth feature is proposed, in which reinforcing ribs extending in the input direction of the collision load are formed on the resin layer.

  According to the invention, in addition to any one of the seventeenth to twentieth characteristics, a fastening flange made of discontinuous fiber resin in which the pin hole is formed is integrated from the front-rear outer end of the bumper beam extension. A vehicle body structure for an automobile according to a twenty-first feature is proposed in which the front end side of the fastening flange is inclined outward in the front-rear direction.

  The front side frame front portion 14 of the embodiment corresponds to the vehicle body frame of the present invention, and the bumper beam extension 18 and the bumper beam 19 of the embodiment correspond to the shock absorbing member of the present invention. The first pin 33g corresponds to the pin of the present invention, the second pin 33k of the embodiment corresponds to the pin of the present invention, and the vertical rib 33f, the first reinforcing ribs 51f and 52f, and the second reinforcing rib 51h of the embodiment. , 52h and the third reinforcing ribs 51i, 52i correspond to the reinforcing ribs of the present invention, and the front fastening flanges 51b, 52b and the rear fastening flanges 51c, 52c of the embodiment correspond to the fastening flanges of the present invention.

  According to the first aspect of the present invention, the shock absorbing member of an automobile is formed by bonding continuous fibers oriented in a lattice shape in a first direction and a second direction perpendicular thereto with a first thermoplastic resin. On both surfaces of the continuous fiber reinforced resin layer, a discontinuous fiber reinforced resin layer obtained by bonding randomly oriented discontinuous fibers with a second thermoplastic resin is laminated. The shock absorbing member shows a large strength against the collision load input in the first direction or the second direction, but when the collision load in the oblique direction is input, the lattice shape of the continuous fiber is deformed out of plane and breaks at the intersection. As a result, the strength decreases. However, by making the length of the randomly oriented discontinuous fibers longer than the diagonal length of the continuous fiber lattice, the continuous fiber lattice is effectively reinforced with discontinuous fibers when an oblique collision load is input. Thus, it is possible to suppress out-of-plane deformation, increase the compressive fracture strength of the impact absorbing member, and enhance the impact absorbing effect against the collision load input from various directions.

  According to the second feature of the present invention, since the continuous fiber reinforced resin layer has a fragile portion that partially lowers the strength, the buckling strength of the shock absorbing member is locally reduced and transmitted to the vehicle body frame. While the peak load is reduced, the shock absorption amount of the shock absorbing member can be secured by the discontinuous fiber reinforced resin layer laminated on the continuous fiber reinforced resin layer.

  According to the third feature of the present invention, since the continuous fiber reinforced resin layer is composed of a plurality of layers including a layer having a fragile portion and a layer not having a fragile portion, the influence of providing the fragile portion is minimized. It is possible to secure a sufficient amount of shock absorption by the shock absorbing member.

  According to the fourth aspect of the present invention, the discontinuous fiber reinforced resin layer wraps all both sides and ends of the continuous fiber reinforced resin layer, so that the continuous fiber reinforced resin layer breaks from the ends in the initial stage of the oblique collision. This can be avoided by reinforcing the end with a discontinuous fiber reinforced resin layer.

  According to the fifth feature of the present invention, since the first thermoplastic resin is nylon and the second thermoplastic resin is polypropylene, the moisture-sensitive nylon is covered and protected with moisture-resistant polypropylene. Can do.

  Further, according to the sixth feature of the present invention, the discontinuous fiber reinforced resin layer includes a press-molded reinforcing rib, so that the reinforcing rib can be easily formed with discontinuous fibers having high moldability, The strength can be increased by increasing the moment of inertia of the cross section of the shock absorbing member by the reinforcing rib.

  According to the seventh feature of the present invention, the discontinuous fibers of the discontinuous fiber reinforced resin layer are obtained by cutting the impact absorbing member into a predetermined length, and therefore, the continuous impact absorbing member to be discarded. The fiber can be recycled as a discontinuous fiber of a new shock absorbing member.

  According to an eighth aspect of the present invention, the bumper beam extension disposed between the vehicle body frame extending in the front-rear direction and the bumper beam extending in the vehicle width direction includes an upper member having a hat-shaped cross section when viewed in the front-rear direction. Consisting of the lower member, the edge of the joint flange formed at both ends in the vehicle width direction of the upper member and covered with the discontinuous fiber reinforced resin layer, and the discontinuous fiber reinforced resin layer formed at both ends in the vehicle width direction of the lower member Because the laser welding is performed by superimposing the edges of the joint flange covered with, the upper and lower members can be firmly bonded without using a highly adhesive transparent resin for the resin in the discontinuous fiber reinforced resin layer. Can do.

  According to the ninth feature of the present invention, since the first reinforcing rib is integrally projected from the edge of the joining flange of the discontinuous fiber reinforced resin layer, the first reinforcing rib is formed with discontinuous fibers having high formability. Not only can it be molded easily, but the strength of the bumper beam extension can be increased by increasing the second moment of section of the bumper beam extension by means of reinforcing ribs.

  According to the tenth feature of the present invention, the second reinforcing rib extending in the front-rear direction from the discontinuous fiber reinforced resin layer covering the outer surfaces of the upper member and the lower member is integrally projected, and the upper member and the lower member Since the third reinforcing ribs extending in a direction inclined with respect to the front-rear direction from the discontinuous fiber reinforced resin layer covering the inner surface of the first and second reinforcing ribs are integrally projected, the second and third reinforcing ribs are formed of discontinuous fibers having high formability. Not only can it be easily molded, but the strength of the bumper beam extension can be increased by increasing the cross-sectional second moment of the bumper beam extension, and the second and third reinforcing ribs extending in different directions can be input from various directions. It is possible to enhance the impact absorbing effect against the collision load.

  According to the eleventh feature of the present invention, the fastening flanges extending in the vertical direction from the front end and the rear end of the discontinuous fiber reinforced resin layer covering the outer surfaces of the upper member and the lower member are integrally projected, and the front side and the rear side Since the fastening flanges on the side are connected by the second reinforcing ribs, the fastening flange can be easily formed with discontinuous fibers having high formability, and the bumper beam extension is firmly coupled to the bumper beam and the vehicle body frame. In addition, the collision load input from the bumper beam can be efficiently transmitted to the vehicle body frame by the reinforcing rib.

  According to the twelfth feature of the present invention, since the nut for coupling the bumper beam is inserted into the front fastening flange, the workability when coupling the bumper beam to the bumper beam extension can be improved.

  According to the thirteenth feature of the present invention, the front end of the fastening flange is inclined outward in the front-rear direction, so that the collision load input from the bumper beam can be reliably transmitted to the bumper beam extension.

  According to the fourteenth feature of the present invention, the thickness of the discontinuous fiber reinforced resin layer before press molding is t0, the thickness of the general portion of the discontinuous fiber reinforced resin layer after press molding is t1, When the thickness after press molding of the second reinforcing rib and the third reinforcing rib of the continuous fiber reinforced resin layer is set to t2, t1 <t0 <t2 is set. Therefore, in the thin general part, the discontinuous fibers are continuous fiber reinforced resin. In addition to increasing the reinforcement effect against the collision load in the oblique direction by approaching the layer, the thick second and third reinforcing ribs can increase the filling rate of discontinuous fibers and effectively increase the secondary moment of section. Can do.

  According to the fifteenth feature of the present invention, the impact absorbing member is a bumper beam extending in the vehicle width direction, and the bumper beam is formed in a U-shaped cross section that opens the continuous fiber reinforced resin layer toward the outside in the front-rear direction. Since the plurality of U-shaped cross-sections are continuous in the vertical direction and the upper, lower and bottom walls of the U-shaped cross-section are connected by vertical ribs made of discontinuous fiber reinforced resin layers, they are reinforced with vertical ribs. The formed U-shaped cross-section is lightweight and has high bending rigidity and torsional rigidity.

  According to the sixteenth feature of the present invention, the bumper beam includes an initial load absorbing portion that is coupled to the outside in the front-rear direction of the main body, and a pin made of a discontinuous fiber reinforced resin layer is provided on the main body so as to Since the initial load absorbing part is coupled to the main body by melting the head of the pin that penetrates the pin hole formed in the load absorbing part, not only the initial load absorbing part can be easily coupled to the main body but also the bumper beam. Can be made into a closed cross-section to increase the bending rigidity.

  According to the seventeenth feature of the present invention, when a bumper beam made of fiber reinforced resin press-molded in the front-rear direction and a bumper beam extension made of fiber-reinforced resin press-molded in the vertical direction are combined, the bumper beam The pin projecting inward in the front-rear direction is fitted into the pin hole formed in the bumper beam extension, and the bumper beam and bumper beam extension are joined by heat caulking the head of the pin. The bumper beam and the bumper beam extension can be coupled with a simple structure without requiring a simple fastening member. Moreover, since the pins are formed integrally with the bumper beam that is press-formed in the front-rear direction, the pins do not get in the way when the bumper beam is punched, and the pins extend in the front-rear direction, which is the input direction of the collision load. For this reason, the pin due to the collision load can be prevented from being broken, and the bumper beam and the bumper beam extension can be hardly disconnected.

  According to an eighteenth feature of the present invention, the bumper beam includes a discontinuous fiber reinforced resin layer laminated at least on the inner side in the front-rear direction of the continuous fiber reinforced resin layer, and the discontinuous fiber reinforced resin layer integrally includes a pin. Therefore, a pin that is difficult to mold with a continuous fiber reinforced resin layer with low moldability can be easily molded with a discontinuous fiber reinforced resin layer with high moldability, and the pins are sufficiently reinforced with discontinuous fibers. The bumper beam and the bumper beam extension can be firmly fixed.

  According to the nineteenth feature of the present invention, the bumper beam and the bumper beam extension include a continuous fiber reinforced resin layer in which the continuous fibers are oriented in two directions orthogonal to each other. Therefore, the bumper beam and the bumper beam extension are bent. Not only can the strength be increased, but also the impact absorbing performance can be improved by sequentially crushing the bumper beam and the bumper beam extension from the tip side when a collision load is input.

  According to a twentieth feature of the present invention, the bumper beam and the bumper beam extension include a discontinuous fiber reinforced resin layer laminated on the continuous fiber reinforced resin layer, and the discontinuous fiber reinforced resin layer has an input direction to a collision load. Reinforcing fiber ribs that extend in the direction of the resin can be easily formed with discontinuous fiber reinforced resin with excellent moldability, and the reinforcing ribs increase the moment of inertia of the bumper beam and bumper beam extension. Thus, not only can the bending strength be increased, but also the impact absorbing performance can be increased by crushing the reinforcing ribs.

  According to the twenty-first feature of the present invention, a fastening flange made of discontinuous fiber reinforced resin having pin holes formed integrally projects from the front-rear outer end of the bumper beam extension, and the front end of the fastening flange is front-rear. Since it inclines outward, when the collision load is input from the bumper beam to the fastening flange of the bumper beam extension, the collision load can be efficiently received by the fastening flange. As a result, the bumper beam extension is sequentially crushed from the front end side by using the fastening flange as a trigger (a trigger for breakage), and the shock absorbing performance of the bumper beam extension can be maximized.

FIG. 1 is a perspective view of a front part of a vehicle body. (First embodiment) FIG. 2 is a view in the direction of the arrow 2 in FIG. (First embodiment) FIG. 3 is a perspective view of the bumper beam. (First embodiment) FIG. 4 is an enlarged view of part 4 of FIG. (First embodiment) FIG. 5 is an enlarged view of part 5 of FIG. (First embodiment) 6 is a cross-sectional view taken along line 6-6 of FIG. (First embodiment) 7 is a cross-sectional view taken along line 7-7 of FIG. (First embodiment) FIG. 8 is an exploded perspective view of the bumper beam extension. (First embodiment) 9 is a view taken in the direction of arrows 9 (A) to 9 (D) in FIG. (First embodiment) FIG. 10 is an explanatory diagram of a bumper beam extension manufacturing method. (First embodiment) FIG. 11 is a schematic cross-sectional view of the bumper beam extension. (First embodiment) FIG. 12 is a diagram for explaining the operation when an oblique load is input. (First embodiment) FIG. 13 is a schematic diagram showing the relationship between the lattice of continuous fibers and the length of discontinuous fibers. (First embodiment) FIG. 14 is an explanatory view of cutting for recycling the shock absorbing member. (First embodiment) FIG. 15 is a diagram for comparing the effects of the present invention and the comparative example. (First embodiment) FIG. 16 is a schematic cross-sectional view of the bumper beam extension. (Second Embodiment) FIG. 17 corresponds to FIG. (Third embodiment) FIG. 18 is an explanatory diagram of a method for manufacturing the main body of the bumper beam. (Third embodiment) FIG. 19 is a diagram for explaining the operation when a collision load is input. (Third embodiment)

14 Front side frame front (body frame)
18 Bumper beam extension (shock absorbing member)
18a Laser welding 19 Bumper beam (Shock absorbing member)
31 Main body portion 32 Initial load absorbing portion 32d Pin hole 33 U-shaped cross section 33a Upper wall 33b Lower wall 33c Bottom wall 33f Vertical rib (reinforcing rib)
33g First pin (pin)
33k Second pin (pin)
51 Upper member 51b Front fastening flange (fastening flange)
51c Rear fastening flange (fastening flange)
51d Joining flange 51e Joining flange 51f First reinforcing rib (reinforcing rib)
51h Second reinforcing rib (reinforcing rib)
51i Third reinforcing rib (reinforcing rib)
51m Pin hole 52 Lower member 52b Front fastening flange (fastening flange)
52c Rear fastening flange (fastening flange)
52d Joining flange 52e Joining flange 52f First reinforcing rib (reinforcing rib)
52h Second reinforcing rib (reinforcing rib)
52i Third reinforcing rib (reinforcing rib)
52 m Pin hole 53 Continuous fiber reinforced resin layer 53a Fragile portion 54 Discontinuous fiber reinforced resin layer 61 Continuous fiber 62 Continuous fiber 63 Discontinuous fiber 64 Nut

Mode for carrying out the invention

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

First embodiment

  First, a first embodiment of the present invention will be described with reference to FIGS. In the present specification, the front-rear direction (impact load input direction), the left-right direction (vehicle width direction), and the up-down direction are defined with reference to the passenger seated in the driver's seat.

  As shown in FIGS. 1 and 2, the automobile body of the embodiment includes a cabin 11 integrally formed in a bathtub shape with FRP such as GFRP (glass fiber reinforced resin), and a dash panel 12 standing from its front end. A pair of left and right suspension support members 13, 13 that are die-cast with an aluminum alloy are fixed to the front surface. The suspension support members 13 and 13 include damper housings 13a and 13a that support upper ends of suspension dampers (not shown), and front side frame rear portions 13b and 13b that are connected to lower portions of the damper housings 13a and 13a and extend forward. A pair of left and right front side frame front parts 14, 14 made of an aluminum extruded material or a steel plate press material are connected to the front ends of the front side frame rear parts 13b, 13b. A pair of left and right FRP side members 16, 16 are connected to front ends of a pair of left and right FRP upper members 15, 15 extending forward from the left and right upper portions of the dash panel 12.

  A front bulkhead 17 made of FRP formed in a rectangular frame shape in front view is fixed to the front ends of the front side frame front portions 14, 14, and the front ends of the side members 16, 16 are located on the upper left and right sides of the front bulkhead 17. Connected. A pair of left and right FRP bumper beam extensions 18, 18 are fixed to the front ends of the front side frame front portions 14, 14, and an FRP bumper beam 19 extending in the vehicle width direction at the front ends of the bumper beam extensions 18, 18. Is fixed. The front surface of the bumper beam 19 is covered with a bumper face 20. An FRP shroud 21 formed in a rectangular frame shape when viewed from the front is disposed at a position surrounded by the front bulkhead 17, the bumper beam 19, and the pair of left and right bumper beam extensions 18, 18. Further, cooling system components (not shown) such as an engine cooling radiator, an air conditioning condenser, and a battery cooling radiator are overlapped and supported in the front-rear direction.

  Next, the structure of the bumper beam 19 is demonstrated based on FIG. 3 and FIG.

  The bumper beam 19 made of FRP includes a rear body portion 31 and front initial load absorbing portions 32. The main body 31 includes a pair of U-shaped cross-sections 33, 33 that have an upper wall 33a, a lower wall 33b, and a bottom wall 33c and that open toward the front. The upper flange 33d and the lower flange 33e of the upper U-shaped section 33 are overlapped in the front-rear direction and welded together to form a substantially W-shaped section. Inside the U-shaped cross-section 33, a plurality of vertical ribs 33f that extend in the vertical direction and connect the upper wall 33a, the lower wall 33b, and the bottom wall 33c are separated by a predetermined distance in the longitudinal direction of the bumper beam 19. Formed. The upper flange 33d of the upper U-shaped cross section 33 and the lower flange 33e of the lower U-shaped cross section 33 are formed with a plurality of first pins 33g that protrude forward. A plurality of fastening collars 34 are inserted into the bottom wall 33c of the U-shaped cross section 33.

  The initial load absorbing portions 32 are divided into three in the longitudinal direction of the bumper beam 19, and each has substantially the same structure. Each initial load absorbing portion 32 includes a flat connecting wall 32a, and a plurality of vertical ribs 32b and a plurality of horizontal ribs 32c formed on the front surface of the connecting wall 32a. The vertical ribs 32b extending in the vertical direction and the horizontal ribs 32c extending in the left-right direction intersect with each other in a lattice shape. Pin holes 32d, into which the first pins 33g of the main body 31 can be fitted, are formed on the upper and lower edges of the connecting wall 32a. The first pins 33g of the main body 31 are fitted into the pin holes 32d of the initial load absorbing portion 32 and the first pins 33g are melted with a vibration tool, so that the initial load absorbing portion 32 is attached to the main body 31. Combined.

  Next, the structure of the bumper beam extension 18 will be described with reference to FIGS.

  The bumper beam extension 18 is configured by vertically coupling an upper member 51 and a lower member 52 having a hat-like cross section in a front view. Since the upper member 51 and the lower member 52 of the bumper beam extension 18 have a substantially plane symmetrical structure, the structure will be described below with the upper member 51 as a representative.

  As shown in FIG. 7, the upper member 51 includes a continuous fiber reinforced resin layer 53 and discontinuous fiber reinforced resin layers 54 and 54 that cover the outer surface and the inner surface of the continuous fiber reinforced resin layer 53. As shown in FIGS. 8 and 10, the second prepreg 59 for forming the continuous fiber reinforced resin layer 53 is a continuous fiber 61, 62 of glass fiber UD (a sheet in which continuous fibers are aligned in one direction). Is formed by laminating three layers in a 0 ° direction, a 90 ° direction, and a 0 ° direction as a reinforcing material and impregnating them with a thermoplastic resin (nylon 6 or nylon 66). The 0 ° direction refers to a state in which the bumper beam extension 18 is mounted on the vehicle body, the UD extends in the front-rear direction (including the vertical direction), and the 90 ° direction refers to a state in which the bumper beam extension 18 is mounted on the vehicle body. It refers to a state in which UD extends in the vehicle width direction (including the vertical direction). The length of one side of the lattice shape formed by the continuous fibers 61 in the 0 ° direction and the continuous fibers 62 in the 90 ° direction is, for example, 5 mm.

  On the other hand, the first and third prepregs 58 and 60 for forming the discontinuous fiber reinforced resin layers 54 and 54 laminated on both surfaces of the continuous fiber reinforced resin layer 53 are mats of glass fiber discontinuous fibers 63. Reinforcing materials are formed by impregnating them with a thermoplastic resin (polypropylene or the like). The length L2 of the discontinuous fibers 63 is equal to or longer than the length L1 (for example, 7.1 mm) of the lattice-shaped diagonal line formed by the continuous fibers 61, 62, etc. in the 0 ° direction and the 90 ° direction (see FIG. 8). ). Although the length of the discontinuous fibers 63 varies, the length of the discontinuous fibers 63 in the present invention is defined as an average value thereof.

  As shown in FIG. 14, the discarded bumper beam extension 18 is cut into chips at intervals longer than the diagonal length L1, and the continuous fibers 61, 62, ... contained therein are cut. The discontinuous fibers 63 can be recycled as the discontinuous fibers 63. Thereby, the continuous fibers 61... 62... More expensive than the discontinuous fibers 63 can be reused to contribute to cost reduction.

  The upper member 51 is manufactured as follows. As shown in FIG. 10A, a mold 55 for press-molding the upper member 51 of the bumper beam extension 18 includes a female die 56 having a concave cavity 56a for molding the outer surface of the upper member 51, and the upper member 51. Are formed in the cavity 56a and the core 57a, and grooves 56b, 57b,... Are formed in the cavity 56a and the core 57a. The mold 55 is opened to preheat the discontinuous fiber reinforced resin first prepreg 58, the continuous fiber reinforced resin second prepreg 59, and the discontinuous fiber reinforced resin third prepreg 60 on the female mold 56. The fiber reinforced resin product of the bumper beam extension 18 is obtained when the male mold 57 is clamped and pressure-molded and then cooled and then cooled.

  FIG. 11 schematically shows a cross section of the bumper beam extension 18. Both surfaces of the central continuous fiber reinforced resin layer 53 are covered with discontinuous fiber reinforced resin layers 54 and 54. The continuous fiber reinforced resin layer 53 is formed with fragile portions 53a by cutting into a part thereof. Instead of forming the fragile portions 53a by cutting, the surface treatment for increasing the adhesive strength between the continuous fibers 61, 62, etc. of the continuous fiber reinforced resin layer 53 and the resin is partially disabled to make the fragile The portions 53a ... may be formed.

  The upper member 51 having a hat-shaped cross section formed as described above includes a main body 51a, a front fastening flange 51b that bends upward from the front edge of the main body 51a, and a rear that is bent upward from the rear edge of the main body 51a. A fastening flange 51c and a pair of joining flanges 51d and 51e extending inward and outward in the vehicle width direction from both ends in the vehicle width direction of the main body 51a are provided. First reinforcing ribs 51f and 51f bent upward are integrally formed at the ends in the vehicle width direction of the pair of joining flanges 51d and 51e, and the front surface is fastened to the outer surface of the main body 51a by extending in the front-rear direction. Two second reinforcing ribs 51h, 51h that connect the flange 51b and the rear fastening flange 51c are formed, and three third reinforcing ribs 51i that intersect in three directions at intervals of 60 ° are formed on the inner surface of the main body 51a. Is formed. Further, three nuts 64 are inserted into the front fastening flange 51b, and three fastening holes 51j are formed in the rear fastening flange 51c.

  Since the lower member 52 has the same shape that is substantially plane-symmetric with the upper member 51 described above, the same subscript as the subscript of each part of the upper member 51 is added to the reference numeral 52 of the lower member 52 so as to overlap. Description is omitted. The bumper beam extension 18 formed by joining the joining flanges 51d and 51e of the upper member 51 and the joining flanges 52d and 52e of the lower member 52 constitutes each cylindrical closed section extending in the front-rear direction.

  When the male mold 57 is lowered with respect to the female mold 56 in the process of press-molding the bumper beam extension 18, the second prepreg 59 is pressed by the cavity 56a of the female mold 56 and the core 57a of the male mold 57, and the upper member 51 (or the lower member 52) is molded. At this time, since the first and third prepregs 58 and 60 using the discontinuous fiber as a reinforcing material can be easily deformed, the first prepreg 58 sandwiched between the second prepreg 59 and the cavity 56a of the female die 56 is The first reinforcing ribs 51f and 51f, the front fastening flange 51b, the rear fastening flange 51c, and the second reinforcing ribs 51i and 51i are simultaneously molded and the outer surface of the upper member 51 A thin film is laminated along the entire surface. Similarly, the third prepreg 60 sandwiched between the second prepreg 59 and the core 57a of the male mold 57 flows into the grooves 57b of the core 57a, and simultaneously passes through the third reinforcing ribs 51i of the inner surface of the upper member 51. While being molded, the thin film is laminated along the inner surface of the upper member 51.

  All end portions of the continuous fiber reinforced resin layer 53 are covered with discontinuous fiber reinforced resin layers 54 and 54 that wrap around from the surface of the continuous fiber reinforced resin layer 53. The thickness of the first and third prepregs 58, 60 before press molding is t0, the thickness of the general part after press molding (the portion covering the continuous fiber reinforced resin layer 53) is t1, and the first reinforcing ribs 51f, When the thicknesses of 51f, the second reinforcing ribs 51h, 51h, and the third reinforcing ribs 51i are t2, t1 <t0 <t2 is set (see FIG. 10B). That is, when the first and third prepregs 58 and 60 are press-molded, the thickness t0 is reduced, and the thickness of the general portion becomes t1 thinner than t0, and the first and third prepregs 58 are excessive. The first reinforcing ribs 51f, 51f, the second reinforcing ribs 51h, 51h, and the third reinforcing ribs 51i,..., 60 formed by being extruded are t2 which is larger than t0.

  It should be noted that the inner surfaces of the joining flanges 51d and 51e of the upper member 51 and the joining flanges 52d and 52e of the lower member 52 (portions that are in contact with each other) are not covered with the discontinuous fiber reinforced resin layers 54 and 54 and are continuous fiber reinforced resin. Although the layer 53 is exposed, since the continuous fiber reinforced resin layer 53 is not exposed when the upper member 51 and the lower member 52 are joined together, the entire surface of the bumper beam extension is eventually covered with the discontinuous fiber reinforced resin layers 54 and 54. It will be.

  The continuous fiber reinforced resin layer 53 having a long fiber UD as a reinforcing material has a relatively high strength. However, since the amount of deformation of the UD is limited, the moldability is low, and a thin, high rib is formed. Is difficult. On the other hand, the discontinuous fiber reinforced resin layers 54 and 54 having short fibers randomly entangled as a reinforcing material have a relatively low strength, but because the fibers are easily deformed, the moldability is high, and the thin and high ribs. Etc. are easy to mold. Accordingly, the upper member 51 and the lower member 52 are formed by laminating the discontinuous fiber reinforced resin layers 54 and 54 on the continuous fiber reinforced resin layer 53, thereby making the strength and formability of the upper member 51 and the lower member 52 compatible. be able to.

  Similar to the bumper beam extension 18 described above, the main body 31 of the bumper beam 19 has a structure in which the entire surface of the continuous fiber reinforced resin layer 53 is covered with discontinuous fiber reinforced resin layers 54, 54. Molded in the same way as the extension 18.

  The upper member 51 and the lower member 52 having the above-mentioned shapes are integrally coupled by laser welding 18a, 18a (see FIG. 7) of their joining flanges 51d, 51e, 52d, 52e. When the upper member 51 and the lower member 52 are bonded together, it is necessary to use a transparent resin having high adhesiveness as the resin constituting the discontinuous fiber reinforced resin layers 54, 54. It is no longer necessary to use a transparent resin.

  Next, the mounting structure of the bumper beam extension 18 to the front bulkhead 17 and the bumper beam 19 will be described with reference to FIGS.

  A mounting plate 81 made of a metal plate is welded to the front end of the front side frame front portion 14. Then, six bolts 83 that pass through the rear fastening flanges 51c and 52c of the bumper beam extension 18 from front to rear are screwed into weld nuts 84 provided on the rear surface of the mounting plate 81, so that the bumper beam extension 18 and the front are fixed. The bulkhead 17 is fastened together with the mounting plate 81.

  Further, bolts 85 penetrating through the fastening collars 34 inserted into the main body 31 of the bumper beam 19 from the front to the rear are screwed into nuts 64 inserted into the front fastening flanges 51 b and 52 b of the bumper beam extension 18. The bumper beam 19 is fastened to the front ends of the bumper beam extensions 18 and 18.

  Next, the operation of the first embodiment of the present invention having the above configuration will be described.

  When a light collision load such as a collision with a pedestrian's leg is input to the bumper beam 19, the vertical ribs 32 b and the lateral ribs 32 c of the initial load absorption unit 32 are crushed and exhibit shock absorbing performance. When a large collision load is input due to a frontal collision with another automobile or the like, the main body portion 31 of the bumper beam 19 and the bumper beam extension 18 are crushed and exhibit shock absorbing performance.

  At this time, the first reinforcing ribs 51f, 51f, 52f, 52f, the second reinforcing ribs 51h, 51h, 52h, 52h and the third are formed from the discontinuous fiber reinforced resin layers 54, 54 covering the surfaces of the upper member 51 and the lower member 52. Since the reinforcing ribs 51i, 52i, etc. are integrally projected, not only can the reinforcing ribs be easily formed by the discontinuous fibers 63 having high formability, but the secondary moment of the section of the bumper beam extension 18 can be reduced. The strength can be increased by increasing each of the reinforcing ribs.

  Further, front fastening flanges 51b and 52b and rear fastening flanges 51c and 52c extending in the vertical direction from the discontinuous fiber reinforced resin layers 54 and 54 covering the surfaces of the upper member 51 and the lower member 52 are integrally projected to be fastened. Since the flanges 51b, 52b and the rear fastening flanges 51c, 52c are connected by the second reinforcing ribs 51h, 51h, 52h, 52h (see FIG. 9), the fastening flanges are easily formed with discontinuous fibers having high formability. In addition, the bumper beam extension 18 is firmly coupled to the bumper beam 19 and the front side frame front portion 14, and the collision load input from the bumper beam 19 is front-loaded by the second reinforcing ribs 51h, 51h, 52h, and 52h. It can be efficiently transmitted to the side frame front part 14.

  At that time, nuts 64... For coupling the bumper beam 19 are inserted into the front fastening flanges 51 b and 52 b, so that workability when the bumper beam 19 is coupled to the bumper beam extension 18 can be improved. In addition, since the front ends of the front fastening flanges 51 b and 52 b are inclined toward the front side (see FIG. 6), the rearward collision load input from the bumper beam 19 can be reliably transmitted to the bumper beam extension 18.

  In addition, the thickness of the discontinuous fiber reinforced resin layers 54 and 54 of the upper member 51 and the lower member 52 before press molding is t0, and the thickness of the general portion of the discontinuous fiber reinforced resin layers 54 and 54 after press molding is t1. And the first reinforcing ribs 51f, 51f, 52f, 52f of the discontinuous fiber reinforced resin layers 54, 54, the second reinforcing ribs 51h, 51h, 52h, 52h and the third reinforcing ribs 51i, 52i,. When the thickness is set to t2, t1 <t0 <t2 is set, so that in the thin general part, the discontinuous fibers 63... Are brought closer to the continuous fiber reinforced resin layer 53 to enhance the reinforcement effect against the collision load in the oblique direction. In addition to the thick first reinforcing ribs 51f, 51f, 52f, 52f, the second reinforcing ribs 51h, 51h, 52h, 52h and the third reinforcing ribs 51i. To increase the 3 ... filling rate of can increase the second moment effectively.

  The main body 31 of the bumper beam 19 has two U-shaped cross-sections 33, 33 formed in a U-shaped cross-section that opens the continuous fiber reinforced resin layer 53 facing forward, and is not continuous. Since the upper wall 33a, the lower wall 33b, and the bottom wall 33c of the U-shaped cross-sections 33, 33 are connected by the vertical ribs 33f made of the continuous fiber reinforced resin layers 54, 54, the U shapes reinforced by the vertical ribs 33f. The cross sections 33 and 33 are lightweight and have high bending rigidity and high torsional rigidity.

  Moreover, the bumper beam 19 includes an initial load absorbing portion 32 coupled to the front side of the main body portion 31, and first pins 33 g made of discontinuous fiber reinforced resin layers 54, 54 are projected from the main body portion 31 to absorb the initial load. Since the initial load absorbing portion 32 is coupled to the main body portion 31 by melting the head of the first pins 33g... Passing through the pin holes 32d of the portion 32, the initial load absorbing portion 32 can be easily attached to the main body portion 31. In addition to the coupling, the bumper beam 19 can be closed to increase the bending rigidity.

  The bumper beam extension 18 and the bumper beam 19 described above are continuous fibers 61 arranged in the front-rear direction (including the vertical direction) that is the input direction of the collision load, and the vehicle width direction that is orthogonal to the input direction of the collision load. Discontinuous fibers 63 randomly oriented on both surfaces of a continuous fiber reinforced resin layer 53 in which the continuous fibers 62 arranged in the vertical direction (including the vertical direction) are aligned in a lattice shape and bonded with thermoplastic nylon. Since it is constituted by laminating discontinuous fiber reinforced resin layers 54 and 54 bonded with thermoplastic polypropylene, it has a high strength against a longitudinal load applied in parallel with the orientation direction of one continuous fiber 61. However, as shown in FIG. 12, when a collision load in an oblique direction is input, the lattice shape of the continuous fibers 61... 62.

  However, as shown in FIGS. 8 and 13, the length L2 of the randomly oriented discontinuous fibers 63... Is larger than the diagonal length L1 of the lattice of the continuous fibers 61. When the collision load in the direction is input, the lattice of the continuous fibers 61, 62, ... is effectively reinforced with the discontinuous fibers 63, thereby suppressing the out-of-plane deformation and increasing the compressive fracture strength of the bumper beam extension 18 and the bumper beam 19. Thus, it is possible to enhance the impact absorption effect against the collision load input from various directions.

  Moreover, since the continuous fiber reinforced resin layer 53 has a weakened portion 53a that partially reduces the strength (see FIG. 11), the buckling strength of the bumper beam extension 18 and the bumper beam 19 is locally reduced to reduce the front side frame. It is possible to secure the shock absorption amount of the bumper beam extension 18 and the bumper beam 19 with the discontinuous fiber reinforced resin layers 54 and 54 laminated on the continuous fiber reinforced resin layer 53 while reducing the peak load transmitted to the front portion 14. it can.

  In addition, the discontinuous fiber reinforced resin layers 54 and 54 of the bumper beam extension 18 and the bumper beam 19 wrap around all of both sides and ends of the continuous fiber reinforced resin layer 53, so that the continuous fiber reinforced resin layer 53 is end in the initial stage of the oblique collision. Breaking from the portion can be avoided by reinforcing the end portion with the discontinuous fiber reinforced resin layers 54, 54.

  Further, since the thermoplastic resin of the inner continuous fiber reinforced resin layer 53 is nylon and the thermoplastic resin of the outer discontinuous fiber reinforced resin layers 54 and 54 is polypropylene, the moisture-sensitive nylon is covered with moisture-resistant polypropylene. Can be protected.

  As shown in the comparative example of FIG. 15B, when the impact absorbing member is composed of only the continuous fiber reinforced resin layer 53 in which the first continuous fibers 61 and the second continuous fibers 62 are orthogonal to each other. In the case where the input direction of the collision load coincides with the direction of the first continuous fiber 61... Or the second continuous fiber 62. There is a problem that strength decreases.

  On the other hand, as shown in the embodiment of FIG. 15B, when the impact absorbing member is formed by laminating the discontinuous fiber reinforced resin layers 54 and 54 on the continuous fiber reinforced resin layer 53, the collision load Even if the input direction is inclined, the decrease in strength is suppressed to a small extent, and the impact of the input direction on the collision load can be minimized to ensure stable shock absorbing performance.

Second embodiment

  Next, a second embodiment of the present invention will be described with reference to FIG.

  In the first embodiment described with reference to FIG. 10, the continuous fiber reinforced resin layer 53 having the fragile portions 53 a... Is one layer, but in the second embodiment, the continuous fiber reinforced resin layer having the fragile portions 53 a. 53 and a continuous fiber reinforced resin layer 53 having no fragile portion 53a are laminated in two layers, and discontinuous fiber reinforced resin layers 54 and 54 are laminated on the outside thereof.

  According to the present embodiment, the continuous fiber reinforced resin layers 53, 53 are composed of two layers including a layer having a fragile portion 53a ... and a layer not having the fragile portion 53a ..., so that the fragile portion 53a ... is provided. Therefore, the impact absorption amount of the bumper beam extension 18 and the bumper beam 19 can be sufficiently secured.

Third embodiment

  Next, a third embodiment of the present invention will be described with reference to FIGS. In the first embodiment described above, the bumper beam 19 and the bumper beam extension 18 are coupled by the bolts 85 and nuts 64. However, in the third embodiment, the bumper beam 19 and the bumper beam extension 18 are provided. Bonded by heat caulking.

  As shown in FIG. 17, the bumper beam 19 includes a plurality of upper flanges 33 d of the upper U-shaped section 33 and lower flanges 33 e of the lower U-shaped section 33 that protrude forward. First pins 33g are formed. Further, three second pins 33k that protrude rearward are formed at both ends in the vehicle width direction of the bottom wall 33c of the U-shaped cross section 33. On the other hand, the front fastening flanges 51b and 52b of the bumper beam extension 18 are formed with three pin holes 51m.

  Then, six right and left second pins 33k projecting from the rear surface of the bumper beam 19 are inserted into the pin holes 51m, 52m,... Of the front fastening flanges 51b, 52b at the front end of the bumper beam extension 18, respectively. The bumper beam 19 is fastened to the front ends of the bumper beam extensions 18 and 18 by melting (thermal crimping) 33k.

  The main body 31 of the bumper beam 19 is manufactured as follows. As shown in FIG. 18A, a mold 55 for press-molding the main body 31 of the bumper beam 19 includes a female mold 56 having a concave cavity 56 a for molding the outer surface of the main body 31, and the main body 31. It comprises a male mold 57 having a convex core 57a for molding the inner surface, and grooves 56b, 57b,... For molding ribs and pins are formed in the cavity 56a and the core 57a. The mold 55 is opened to preheat the discontinuous fiber reinforced resin first prepreg 58, the continuous fiber reinforced resin second prepreg 59, and the discontinuous fiber reinforced resin third prepreg 60 on the female mold 56. The fiber reinforced resin product of the main body part 31 is obtained when the male mold 57 is clamped and pressure-molded and then cooled.

  As shown in FIG. 18 (B), the body portion 31 of the bumper beam 19 press-molded by the mold 55 has a continuous fiber reinforced resin layer 53 and a non-cover that covers the outer and inner surfaces of the continuous fiber reinforced resin layer 53. It is composed of continuous fiber reinforced resin layers 54 and 54.

  The second prepreg 59 for forming the continuous fiber reinforced resin layer 53 is composed of glass fibers UD (sheets obtained by aligning continuous fibers in one direction) with continuous fibers 61... 62. A laminate of three layers in the 0 ° direction is used as a reinforcing material, and these are impregnated with a thermoplastic resin (nylon 6 or nylon 66). The 0 ° direction refers to a state in which the bumper beam 19 is attached to the vehicle body, and the UD extends in the front-rear direction (including the vertical direction). The 90 ° direction refers to a state in which the bumper beam 19 is attached to the vehicle body. It refers to a state extending in the vehicle width direction (including the vertical direction).

  On the other hand, the first and third prepregs 58 and 60 for forming the discontinuous fiber reinforced resin layers 54 and 54 laminated on both surfaces of the continuous fiber reinforced resin layer 53 are mats of glass fiber discontinuous fibers 63. Reinforcing materials are formed by impregnating them with a thermoplastic resin (polypropylene or the like).

  The discontinuous fiber reinforced resin layer 54 laminated on the inner surface (front surface) of the main body portion 31 of the bumper beam 19 is integrally formed with vertical ribs 33f... And first pins 33g. The second pins 33k are integrally formed on the discontinuous fiber reinforced resin layer 54 laminated on the outer surface (rear surface).

  When the male mold 57 is lowered with respect to the female mold 56 in the process of press-molding the main body 31 of the bumper beam 19, the second prepreg 59 is pressed by the cavity 56a of the female mold 56 and the core 57a of the male mold 57. The main body 31 is formed. At this time, since the first and third prepregs 58 and 60 using the discontinuous fiber as a reinforcing material can be easily deformed, the first prepreg 58 sandwiched between the second prepreg 59 and the cavity 56a of the female die 56 is The second pins 33k are formed at the same time by flowing into the grooves 56b of the cavity 56a, and are laminated in a thin film shape along a part of the outer surface of the main body 311. Similarly, the third prepreg 60 sandwiched between the second prepreg 59 and the core 57a of the male mold 57 flows into the grooves 57b of the core 57a, and the longitudinal ribs 33f of the inner surface of the main body and the first pins 33g. Are simultaneously formed and laminated in a thin film shape along the entire inner surface of the upper member 51.

  The continuous fiber reinforced resin layer 53 having a long fiber UD as a reinforcing material has a relatively high strength. However, since the amount of deformation of the UD is limited, the moldability is low, and a thin, high rib is formed. Is difficult. On the other hand, the discontinuous fiber reinforced resin layers 54 and 54 having short fibers randomly entangled as a reinforcing material have a relatively low strength, but because the fibers are easily deformed, the moldability is high, and the thin and high ribs. Etc. are easy to mold. Therefore, the strength and formability of the main body 31 of the bumper beam 19 are made compatible by laminating the discontinuous fiber reinforced resin layers 54 and 54 on the continuous fiber reinforced resin layer 53 and molding the main body 31 of the bumper beam 19. be able to.

  Similar to the main body 31 of the bumper beam 19 described above, the bumper beam extension 18 also has a structure in which the upper and lower surfaces of the continuous fiber reinforced resin layer 53 are covered with discontinuous fiber reinforced resin layers 54 and 54, and the bumper beam extension 18 has a structure. The beam 19 is formed by the same method as the main body 31 of the beam 19.

  Next, the operation of the third embodiment of the present invention having the above configuration will be described.

  When the bumper beam 19 press-formed in the front-rear direction and the bumper beam extension 18 press-formed in the up-down direction are coupled, the second pins 33k projecting backward from the bumper beam 19 are connected to the bumper beam extension 18. The bumper beam 19 and the bumper beam extension 18 are joined by fitting into the pin holes 51m, 52m, ... formed in the front fastening flanges 51b, 52b, and melting (thermally crimping) the heads of the second pins 33k ... The bumper beam 19 and the bumper beam extension 18 can be coupled with a simple structure without using a fastening member such as a bolt or a nut.

  Moreover, since the first pins 33g and the second pins 33k are integrally formed on the bumper beam 18 that is press-formed in the front-rear direction, the first and second pins 33g are removed when the main body 31 of the bumper beam 19 is punched. ..., 33k ... do not get in the way, and the first and second pins 33g ..., 33k ... extend in the front-rear direction which is the input direction of the collision load. 33k can be prevented from breaking, and the initial load absorbing portions 32 and the bumper beam extension 18 can be made difficult to be disconnected from the main body portion 31.

  The main body 31 of the bumper beam 19 includes discontinuous fiber reinforced resin layers 54 and 54 laminated on the surface of the continuous fiber reinforced resin layer 53, and the discontinuous fiber reinforced resin layers 54 and 54 include the first pins 33g. Since the two pins 33k are integrally provided (see FIG. 18), the first and second pins 33g, 33k, which are difficult to be molded with the continuous fiber reinforced resin layer 53 with low moldability are discontinuous fiber reinforced with high moldability. The resin layers 54, 54 can be easily molded, and the first and second pins 33g, 33k,... Have sufficient strength to be reinforced with discontinuous fibers, and the bumper beam 19, bumper The beam extension 18 can be firmly coupled.

  Further, the main body 31 and the bumper beam extension 18 of the bumper beam 19 include a continuous fiber reinforced resin layer 53 in which the continuous fibers 61... 62 are oriented in two directions orthogonal to each other (see FIG. 8). 19 and the bumper beam extension 18 can be increased in bending strength, and the bumper beam 19 and the bumper beam extension 18 can be sequentially crushed from the tip side when a collision load is input, thereby improving the impact absorbing performance.

  In addition, the main body 31 of the bumper beam 19 is provided with longitudinal ribs 33f extending in the collision load input direction on the discontinuous fiber reinforced resin layer 54, and the bumper beam extension 18 is input to the discontinuous fiber reinforced resin layer 54 in the collision load input direction. The first reinforcing ribs 51f, 51f, 52f, 52f and the second reinforcing ribs 51h, 51h, 52h, 52h (see FIG. 9) extending in the vertical direction have complicated shapes due to the discontinuous fiber reinforced resin having excellent moldability. The ribs 33f, the first reinforcing ribs 51f, 51f, 52f, 52f and the second reinforcing ribs 51h, 51h, 52h, 52h can be easily formed, and the vertical ribs 33f, the first reinforcing ribs 51f, 51f, 52f, 52f and the second reinforcing ribs 51h, 51h, 52h, 52h, the main body 31 of the bumper beam 19 and the bumps Not only can increase the bending strength by increasing the second moment of over beam extension 18, it is possible to improve the shock absorbing capacity due to their collapse.

  Further, as shown in FIG. 19, the bumper beam extension 18 is provided with front fastening flanges 51b and 52b which are bent in a direction crossing the input direction of the collision load and the discontinuous fibers are hardened with a thermoplastic resin. Since the bumper beam 19 is connected to the fastening flanges 51b and 52b, when a collision load is input from the bumper beam 19 to the bumper beam extension 18, the front fastening flanges 51b and 52b having a large pressure receiving area are triggered (triggering cause of destruction). ) And the bumper beam extension 18 is sequentially crushed in the front-rear direction, so that the shock absorbing performance can be enhanced.

  The embodiments of the present invention have been described above, but various design changes can be made without departing from the scope of the present invention.

  For example, the bumper beam extension and bumper beam of the present invention are not limited to those on the front side of an automobile, and may be those on the rear side.

  Further, the vehicle body frame of the present invention is not limited to the front side frame front portion 14 of the embodiment, and may be a frame disposed in the front-rear direction at the vehicle body front portion or the vehicle body rear portion.

  The FRP of the present invention is not limited to the GFRP (glass fiber reinforced resin) of the embodiment, and may be another type of FRP such as a carbon fiber reinforced resin or an aramid fiber reinforced resin.

  The impact absorbing member of the present invention is not limited to the bumper beam extension 18 and the bumper beam 19 of the embodiment.

  In the embodiment, the two U-shaped cross sections 33 and 33 are combined to form the main body 31 of the bumper beam 19. However, the two U-shaped cross sections 33 and 33 are integrally formed. May be.

Claims (20)

Randomly arranged on both surfaces of a continuous fiber reinforced resin layer (53) in which continuous fibers (61, 62) oriented in a lattice pattern in a first direction and a second direction perpendicular thereto are bonded with a first thermoplastic resin. The discontinuous fiber (63) is formed by laminating a discontinuous fiber reinforced resin layer (54) obtained by bonding discontinuous fibers (63) oriented in a second thermoplastic resin, and the length of the discontinuous fiber (63) is the continuous fiber. An impact absorbing member larger than a diagonal length of the lattice of (61, 62),
In what constitutes the bumper beam (19) extending in the vehicle width direction,
The bumper beam (19) has a plurality of U-shaped cross-section portions (33) formed in a U-shaped cross section that opens the continuous fiber reinforced resin layer (53) toward the outer side in the front-rear direction, and is continuous in the vertical direction. A main body in which the upper wall (33a), the lower wall (33b), and the bottom wall (33c) of the U-shaped cross section (33) are connected by vertical ribs (33f) made of the discontinuous fiber reinforced resin layer (54). A shock-absorbing member for an automobile, comprising a portion (31).   The impact-absorbing member for an automobile according to claim 1, wherein the continuous fiber-reinforced resin layer (53) has a fragile portion (53a) that partially reduces strength.   The automobile according to claim 2, wherein the continuous fiber reinforced resin layer (53) includes a plurality of layers including a layer having the fragile portion (53a) and a layer not having the fragile portion (53a). Shock absorbing member.   The said discontinuous fiber reinforced resin layer (54) wraps all the both surfaces and edge part of the said continuous fiber reinforced resin layer (53), It is any one of Claims 1-3 characterized by the above-mentioned. Shock absorber for automobiles.   The impact-absorbing member for an automobile according to any one of claims 1 to 4, wherein the first thermoplastic resin is nylon and the second thermoplastic resin is polypropylene.   The automobile according to any one of claims 1 to 5, wherein the discontinuous fiber reinforced resin layer (54) includes press-formed reinforcing ribs (51h, 52h, 51i, 52i). Shock absorbing member.   The discontinuous fiber (63) of the discontinuous fiber reinforced resin layer (54) is obtained by cutting the impact absorbing member (18) into a predetermined length. The shock absorbing member for an automobile according to claim 6. Randomly arranged on both surfaces of a continuous fiber reinforced resin layer (53) in which continuous fibers (61, 62) oriented in a lattice pattern in a first direction and a second direction perpendicular thereto are bonded with a first thermoplastic resin. The discontinuous fiber (63) is formed by laminating a discontinuous fiber reinforced resin layer (54) obtained by bonding discontinuous fibers (63) oriented in a second thermoplastic resin, and the length of the discontinuous fiber (63) is the continuous fiber. An impact absorbing member larger than a diagonal length of the lattice of (61, 62),
In the structure of the bumper beam extension (18) disposed between the vehicle body frame (14) extending in the front-rear direction and the bumper beam (19) extending in the vehicle width direction,
The bumper beam extension (18) includes an upper member (51) and a lower member (52) having a hat-like cross section when viewed in the front-rear direction, and is formed at both ends in the vehicle width direction of the upper member (51) to reinforce the discontinuous fiber. Joining formed at the edge of the joining flange (51d, 51e) covered with the resin layer (54) and both ends in the vehicle width direction of the lower member (52) and covered with the discontinuous fiber reinforced resin layer (54) An impact-absorbing member for an automobile, wherein the end edges of the flanges (52d, 52e) are overlapped and joined together.   The first reinforcing rib (51f, 52f) is integrally projected from the end edge of the joining flange (51d, 52d, 51e, 52e) of the discontinuous fiber reinforced resin layer (54). The impact-absorbing member for automobiles described in 1.   Second reinforcing ribs (51h, 52h) extending in the front-rear direction from the discontinuous fiber reinforced resin layer (54) covering the outer surfaces of the upper member (51) and the lower member (52) are integrally projected. Third reinforcing ribs (51i, 52i) extending in a direction inclined with respect to the front-rear direction from the discontinuous fiber reinforced resin layer (54) covering the inner surfaces of the upper member (51) and the lower member (52) are integrated. The impact-absorbing member for an automobile according to claim 8 or 9, wherein the impact-absorbing member is provided on the vehicle.   Fastening flanges (51b, 51c, 52b, 52c) extending vertically from the front end and the rear end of the discontinuous fiber reinforced resin layer (54) covering the outer surfaces of the upper member (51) and the lower member (52). 11. The projection according to claim 10, wherein the first and second fastening flanges (51 h, 52 h) are connected by the second reinforcing ribs (51 b, 51 c, 52 c). Shock absorber for automobiles.   12. The shock absorbing member for an automobile according to claim 11, wherein a nut (64) for coupling the bumper beam (19) is inserted into the front fastening flange (51b, 52b).   The shock absorbing member for an automobile according to claim 12, wherein the front end of the fastening flange (51b, 52b) is inclined toward the outside in the vehicle width direction.   The thickness of the discontinuous fiber reinforced resin layer (54) before press molding is t0, and the thickness of the general part of the discontinuous fiber reinforced resin layer (54) after press molding is t1, and the discontinuous fiber reinforcement is performed. When the thickness after press molding of the second reinforcing ribs (51h, 52h) and the third reinforcing ribs (51i, 52i) of the resin layer (54) is set to t2, t1 <t0 <t2 is set. The impact-absorbing member for an automobile according to any one of claims 11 to 13, wherein the impact-absorbing member is an automobile.   The bumper beam (19) includes an initial load absorbing portion (32) coupled to the outer side in the front-rear direction of the main body portion (31), and the main body portion (31) includes the discontinuous fiber reinforced resin layer (54). By projecting a pin (33g) and melting the head of the pin (33g) penetrating the pin hole (32d) formed in the initial load absorbing portion (32), the main body (31) is The impact absorbing member for an automobile according to any one of claims 1 to 7, wherein the initial load absorbing portion (32) is coupled. The shock absorbing member according to claim 1, wherein the bumper beam (19) made of fiber reinforced resin is press-formed in the front-rear direction, and the impact absorbing member according to claim 8, wherein A vehicle body structure for an automobile that combines a press-molded fiber reinforced resin bumper beam extension (18),
A pin (33k) projecting inward in the front-rear direction from the bumper beam (19) is fitted into a pin hole (51m, 52m) formed in the bumper beam extension (18), and the head of the pin (33k) A vehicle body structure for an automobile characterized in that the bumper beam (19) and the bumper beam extension (18) are coupled by heat caulking.   The bumper beam (19) includes a discontinuous fiber reinforced resin layer (54) laminated at least on the inner side in the front-rear direction of the continuous fiber reinforced resin layer (53), and the discontinuous fiber reinforced resin layer (54) includes the pin ( The vehicle body structure according to claim 17, wherein 33k) is integrally provided.   The bumper beam (19) and the bumper beam extension (18) include a continuous fiber reinforced resin layer (53) in which continuous fibers (61, 62) are oriented in two directions perpendicular to each other. The vehicle body structure according to claim 17 or 18.   The bumper beam (19) and the bumper beam extension (18) include a discontinuous fiber reinforced resin layer (54) laminated on the continuous fiber reinforced resin layer (53), and the discontinuous fiber reinforced resin layer (54). The vehicle body structure of the automobile according to claim 19, wherein reinforcing ribs (33f, 51f, 52f, 51h, 52h) extending in the input direction of the collision load are formed on the body.   Discontinuous fiber resin fastening flanges (51b, 52b) in which the pin holes (51m, 52m) are formed project integrally from the front and rear outer ends of the bumper beam extension (18), and the fastening flanges (51b The vehicle body structure according to any one of claims 17 to 20, wherein the front end side is inclined outward in the front-rear direction.

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